Open pore foam faucet insert



Feb. 18, 1969 R. B. DUGGAN OPEN PORE FOAM FAUCET INSERT Filed March 23,1966 INVENTOR Robert B. Duggan ATTORNEY United States Patent O 3,428,258OPEN PORE FOAM FAUCET INSERT Robert B. Duggan, Louisville, Ky., assignorto American Standard Inc., New York, N .Y., a corporation of DelawareContinuation-impart of abandoned application Ser. No. 414,686, Nov. 30,1964. This application Mar. 23, 1966, Ser. No. 543,459 U.S. Cl.Z39-590.3 Int. Cl. B05b 1/22; E03c 1/108 6 Claims ABSTRACT OF THEDISCLOSURE This application is a continuation-in-part of applicationSer. No. 414,686, filed on Nov. 30, 1964, now abandoned.

This invention relates in general to a method and apparatus forcontrolling the fiow of fluid through a faucet, and more specifically toa method and apparatus for transforming the turbulent flow of waterthrough a faucet into a smooth laminar fiow to define a silent,uninterrupted, non-splashing stream of water discharging therefrom.

Many objections have been raised as to the noise and splash generallycreated by a stream of water discharging from a faucet. Such noise andsplash is attributed to the turbulence created in the flow of water. Theturbulence thus created effects a distortion in the water pattern as itstreams from the spout end of a faucet. Distortion of the water patternin streaming from the faucet is also attributed to the entrappment ofair as the water escapes therefrom.

It is therefore an object of this invention to provide a method andapparatus for transforming the turbulent flow of water through a faucetinto a smooth laminar stream so that it discharges therefrom in asmooth, uniform, and well defined pattern in a relatively silent manner.

It is another object to provide an improved spout end construction. forafaucet that results in forming smooth clear symmetrical, uninterruptedand silent flowing stream as it discharges therefrom in a relativelysimple and expedient manner.

Another object is to provide an improved spout end construction that isrelatively simple to fabricate, relatively inexpensive to manufacture,and which is positive in operation. v

A feature of this invention resides in the provision of a means locatedin the spout end of a faucet, which is constructed to minimize theentrapment of air in the stream of water as it discharges from the spoutend.

Another feature of this invention resides in utilizing an open porematerialror open cellular foam in the spout end of a faucet fortransforming the turbulent flow of fluid therethrough into a smoothlaminar flow to result in a silent, non-splashing ow of water therefrom.

Another feature of this invention resides in the provision of a methodand apparatus utilizing an open pore or cellular material which isreadily disposable and expend- 3,428,258 Patented Feb. 18, 1969 ICC ablein the event it clogs up to effect a smooth, silent, non-splashing fiowof fluid passing therethrough.

Other features and advantages will become more readily apparent whenconsidered in View of the drawings and specifications in which:

FIG. 1 illustrates a cross sectional View of the improved spout end`construction of the instant invention.

FIG. 2 is a sectional view taken along line 2-2 of FIG. 1. f

In accordance with this invention, the method utilized for transformingthe turbulent flow of a fluid, as for example water through a faucet 10or the like, into a smooth laminar flow to result in a welldefined,silent non-splashing stream pattern fiowing therefrom comprises thepositioning in the spout end 11 of a faucet 10 a plug like member, orlayers thereof, formed of an open pore or reticulated cellular foammaterial 12. For example, a polyurethane open-pore foam manufactured bythe Scott Paper Company of Chester, Pa. has been discovered to be a mostsatisfactory material for accomplishing the desired results. Preferably,the plug 12 is formed or blanked from a sheet of open pore cellularmaterial of the required thickness to a size approximating or conformingto the internal diameter Do or circumference of the spout end or nozzle.If desired, a pair of spaced screens or perforated member 13 and 14 maybe used above and below the plug 12.

The open pore cellular foam material is to be distinguished from theopen cell foam in that the open cell foam has a membrane that partiallycovers the cell faces or pores. This type of material has a relativelyhigh pressure drop as compared to the open pore reticulated foammaterial and also acts as a filtering media, which is not desired inthis invention. The example of open pore foam manufactured by the ScottPaper Company of Chester, Pa., cited above, is such a reticulated foamhaving 97% or more of void space and therefore a very low pressure dropthrough the foam. Also no 'further treatment of the foam material .12 isrequired. All that is necessary is that it be cut or blanked to shapeand positioned within the dis-charge end 11 of a faucet 10.

Referring to the drawings, there is shown in FIG. 1 the spout 9 of thefaucet 10 to which the nozzle or spout end 11 is secured. The nozzle 11may be externally threaded at one end 16 thereof to form with the thethreaded opening 18 of the faucet spout 9 a screw connection by which itmay be secured thereto. The other end of the tubular member 11 isprovided with an inturned flange 22 to define an orifice or dischargeopening 24.

In accordance with this invention, a plug or layer of open pore orcellular foam materials 12 is disposed within the bore of the tubularmember 11.

As best seen in FIGS. 1 and 2, the shape of the layer or plug 12 isdefined by an outside diameter that closely conforms `or approximatesthe internal diameter Do of the tubular member 11. Accordingly, toretain the plug or layer 12 of open pore material within the bore of thetubular member 11, the layer of material 12 may be disposed between apair of spaced screen or semirigid perforated members 13, 14.Alternatively, perforations may be provided in the end of the nozzle 11instead of using the screen 13. Also the upper screen 14 may be omittedif desired. With the construction thus described, it has been discoveredthat turbulent liow of water through the faucet is transformed into asmooth laminar flow as the water passes through the layer of open porematerial.

That the structure above described will result in laminar flow to form asilent, non-splashing flow will be evident since the type of fiow,whether turbulent or laminar, is a function of the Reynolds number Nrwhere:

N r:D Vp/ n wherein: D=diameter of opening V=velocity p=densityn=viscosity Thus, given a water flow at a specified temperature Nr=KDVwhere K is a constant.

Since high Reynolds numbers are associated with turbulent flow and lowReynolds numbers with laminar fiow, it will be noted that assuming agiven open porc foam structure wherein the open cell has a dimensionDc=1/50Do and a free area of the foam of 90%, the Reynolds number withno foam equals:

N,.=KDOV, and with foam N,=KDV/90% Substituting for D,3 in the latterequation:

Nr=K(D) /50.V/.9 Nr: 1/45KD0V or Nr (with foam)=1/45 Nr (without foam)From this example, it will be observed that open cell foam willmaterially reduce the Reynolds number, and therefore by proper selectionof diameters and flow rates, the fiow can be changed from turbulent tolaminar by the utilization of open cell foam.

The present range of pore size commercially available extends from to100 p.p.i. (pores per lineal inch), however, it has been determined thatthere is little effect on the appearance of the discharging stream orfiow of water when pore sizes smaller than p.p.i. are used. This is tobe considered the preferred pore size with a range of from 10 to 25p.p.i. being the critical klimits in order to avoid excessive pressuredrop and a filtering action of the material.

From the foregoing description, it will be readily apparent that theutilization of open pore cellular foam material in the spout end of afaucet greatly enhances the establishment of smooth, uninterrupted, flowof water as it discharges therefrom. The well defined uninterruptedstream pattern resulting thereby effects a noiseless and non-splashingstream which is considered to be superior to known present devices. Withthe structure described, it will be further noted that the layer of openpore foam material constitutes a relatively inexpensive means fortransforming turbulent fiow into laminar fiow. Further, the foammaterial is rendered readily expendable in the event that it clogs upwith impurities, which are filtered out as the water passestherethrough. The economics of the foam material render it readilyexpendable, and easily replaceable. Consequently, the foam materialconstitutes a very inexpensive and eiiicient means for transforming aturbulent flow of water into a smooth laminar fiow to result in thesymmetrical uninterrupted stream pattern which is silent andnon-splashing.

While the instant invention has been described with reference to aparticular embodiment thereof, it will be readily appreciated andunderstood that variations and modifications may be made withoutdeparting from the spirit and scope of the invention.

What is claimed is:

1. For use in a faucet, a means for transforming the turbulent fiow ofwater through a faucet into a smooth, silent laminar ow t0 form a welldefined stream discharging therefrom comprising.

(a) a nozzle connected to the discharge end of the faucet.

(b) and a layer of open pore foam disposed within said nozzle, said foamhaving a pore size within the range of from 10 to 25 pores per linealinch, whereby the water flowing through said faucet is caused to fiowthrough said foam in discharging therefrom.

2. A structure as defined in claim 1 wherein said layer of open porefoam is co-extensive in area with the area of the said nozzle.

3. A structure as defined in claim 2 wherein means are disposed in saidnozzle for retaining said layer of foam in position therein.

4. A structure as defined in claim 3 wherein said retaining meansincludes a perforated member disposed below said layer of open porefoam.

5. A method of transforming the turbulent fiow of water through a faucetinto a silent, laminar flow to form a smooth, well defined stream as thewater discharges therefrom comprising the steps of:

(a) positioning a layer of open cellular foam material having a poresize within the range of from 10 to 25 pores per lineal inch in thedischarge end of the faucet so that the water fiowing therethrough isrequired to pass through said layer.

(b) and securing said layer in position within the discharge end of saidfaucet to resist dislodgement thereof by the pressure of water flowingtherethrough.

6. A method forming a means for transforming the turbulent liow of waterthrough a faucet into a silent laminar fiow to form a well defineduninterrupted stream as the water discharges therefrom comprising thesteps of:

(a) forming a plug of open cellular foam from a sheet of cellularmaterial having a pore size within the range of from 10 to 25 pores perlineal inch.

(b) conforming the O D. of the plug to the LD. of a spout end adapted toreceive the same.

(c) positioning the conformed plug of open cellular foam in the spoutend.

(d) and retaining said plug in position in said spout end.

References Cited UNITED STATES PATENTS 883,176 3/1908 Davis 239-552 X924,497 6/ 1909 Perry et al. 1,495,713 5 1924 Phillips 239-552 2,511,4206/ 1950 Thompson 239-343 2,680,010 6/1954 Dubay 239-343 X 2,715,045 8/1955 Thompson 239-343 2,796,297 6/ 1957 Klock 239-124 2,995,309 8/ 1961Moen Z39-428.5

M. HENSON WOOD, JR., Primary Examiner. H. NA'ITER, Assistant Examiner.

U.S. Cl. X.R.

